Encoding Module, Associated Encoding Element, Connector, Printer-Encoder and Access Control System

ABSTRACT

An encoding module and related systems and components are provided. The encoding module includes a plurality of encoding elements arranged in an array of columns and rows and one or more switching elements configured to selectively connect the encoding elements to a reader. The connection of the encoding elements may be based on the location of a targeted transponder disposed among multiple adjacent transponders to ensure the selective communication with the targeted transponder only. The module is configured for various types and locations transponders to be used within a system, such as a printer-encoder. Each encoding element may include a loaded conductive strip comprising a loop shape portion and a shield that corresponds to the loop shape portion. In another embodiment, an access control system having an encoding module with the plurality of couplers and an access card having a plurality of transponders corresponding to the couplers is provided.

CROSS-REFERENCE TO RELATED APPLICATION

This patent arises from a continuation of U.S. patent application Ser.No. 14/502,815, filed Sep. 30, 2014, which is a continuation of U.S.patent application Ser. No. 12/618,107, filed Nov. 13, 2009, now U.S.Pat. No. 8,878,652. U.S. patent application Ser. Nos. 14/502,815 and12/618,107 are incorporated by reference herein in their entireties.

BACKGROUND

Field of the Invention

The present invention relates to an encoding module and related systemsand components such as encoding elements, RFID printer-encoders, andaccess control systems.

Description of Related Art

Radio frequency identification (“RFID”) transponders, either active(e.g., battery-powered, -assisted, or -supported) or passive (e.g., RFfield activated), are typically used with an RFID reader or similardevice for communicating information back and forth. In order tocommunicate, an antenna of the reader exposes the transponder to a radiofrequency (RF) electromagnetic field or signal. In the case of a passiveUHF transponder, the RF electromagnetic field energizes the transponderand thereby enables the transponder to respond to the reader byre-radiating the received signal back and modulating the field in awell-known technique called backscattering. In the case of an activetransponder, the transponder may respond to the electromagnetic field bytransmitting an independently generated, self-powered reply signal tothe reader.

Problems can occur when interrogating one targeted transpondersurrounded by multiple adjacent transponders regardless on whether thetransponders are field activated or independently powered by an internalenergy source. For example, an interrogating electromagnetic signal mayactivate more than one transponder at a given time. This simultaneousactivation of multiple transponders may lead to collision orcommunication errors because each of the multiple transponders maytransmit reply signals to the reader at the same time.

The challenge of avoiding multiple and simultaneous transponderactivation may be especially acute in some applications. RFIDprinter-encoders are one example. RFID printer-encoders are devicescapable of encoding and printing a series or stream of labels withembedded transponders. A conveyor system is another example of anapplication in which undesirable multiple transponder activation may beacute.

SUMMARY OF VARIOUS EMBODIMENTS

Embodiments include systems, methods, computer readable media, and othermeans for providing an encoding module, associated encoding element,connector, printer-encoder, and access control system. For example,embodiments can include RFID printer-encoders and be capable of encodingand/or printing one or more transponders (individually orsimultaneously) that are embedded in one or more labels. Whenencoding/printing a number of transponders in close proximity to eachother, embodiments discussed herein can be configured to target aparticular transponder. Moreover, embodiments can conserve, among otherthings, space, cost, and weight normally associated with encodingdevices, which have utilized other types of EMF collision managementtechniques or shielding components for alleviating unintentionalmultiple transponder activation. Embodiments of the present inventioncan be configured to encode a much broader range of tag types and meetthe encoding pitch, as well as allow for transponder placementindependence.

For example, according to an embodiment, an encoding element isprovided. The encoding element of this embodiment includes a groundplane, a first dielectric substrate, a conductive strip, a terminatingload, a second dielectric substrate, and a shield. The first dielectricsubstrate is adjacent to the ground plane. A conductive strip isadjacent the first dielectric substrate, extends from an input end to aloaded end, and comprises at least one portion having a loop shape. Theterminating load is in communication with the loaded end of theconductive strip. The second dielectric substrate is adjacent theconductive strip. The shield is adjacent an opposite surface of thesecond dielectric substrate from the conductive strip and generallycorresponds to the at least one portion having a loop shape of theconductive strip including providing a central open area.

The conductive strip may include a plurality of portions having a loopshape. Furthermore, each of plurality of portions having a loop shapemay be concentric and coplanar to each other. As another example, theconductive strip may include a first portion having a loop shape and asecond portion having a loop shape. The loop shape of the first portionand the loop shape of the second portion may be non-concentric. Asanother example, the loop shape may be generally rectangular.

In another embodiment, the above encoding element is combined with asecond encoding element. The second encoding element may include atapered microstrip having a length of a one half wavelength, or multiplethereof or be a coplanar waveguide.

In yet another embodiment a system is provided. The system may beconfigured to provide selective communication between a reader and atargeted transponder disposed among multiple adjacent transpondersmoving along a feed path. The system of this embodiment includes areader configured to transmit communication signals and an encodingmodule. The encoding module includes a plurality of encoding elementsarranged in at least one column and a plurality of rows. The at leastone column extends parallel with the feed path and the plurality of rowsextends perpendicular to the feed path.

The system may further include one or more switching elements configuredto selectively connect the plurality of encoding elements to the reader.The system may also include a processor that is configured toselectively connect one of the plurality of encoding elements to thereader through the one or more switching elements based on a location ofthe transponder.

The plurality of encoding elements may include a plurality of columnsand a plurality of rows.

In another embodiment, a method is provided. The method includes movinga media unit having a transponder to a first position; attempting tocommunicate with the transponder of the media unit through at least oneor more of a plurality of encoding elements arranged in an array ofcolumns and rows; and determining an optimal encoding element for thetransponder of the media unit.

The method may further include selecting the optimal encoding element asthe default encoding element for transponders of subsequent media units.The method may also include identifying a reset event associated with asecond media unit and upon identifying the reset event, attempting tocommunicate with the transponder of the second media unit through atleast one or more of the plurality of encoding elements arranged in thearray of columns and rows and determining an optimal encoding elementfor the second media unit.

The operation of attempting to communicate with the transponder of themedia unit through the at least one or more of the plurality of encodingelements arranged in the array of columns and rows may include testingthe at least one or more of plurality of encoding elements according toa sequence based on a likelihood of each encoding element being anoptimal encoding element.

The operation of attempting to communicate with the transponder of themedia unit through the at least one or more of the plurality of encodingelements arranged in the array of columns and rows may includeattempting to communicate with the transponder of the media unit at aplurality of power levels.

The operation of determining the optimal encoding element for thetransponder of the media unit may be based on one or more successfulcommunication attempts and each location of each encoding element inwhich communications was successful or on previously stored informationpertaining to at least one of the following one or more supplies used,the transponder, and an operating environment.

In another embodiment, an access control system is provided. The systemmay include a module and an access card. The module includes a pluralityof encoding elements arranged in a particular manner. The access cardincludes a plurality of transponders arranged in a manner to correspondwith the plurality of encoding elements of the module.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a side schematic view of a printer-encoder according to anembodiment of the present invention;

FIG. 2a is a top view of an encoding element consistent with anexemplary embodiment, wherein the circular dash line 255 represents theconductive strip beneath the shield and the top dielectric substrate;

FIG. 2b is a side view of the encoding element of FIG. 2a taken alongline 2 b;

FIG. 3a illustrates an example of a large dipole-type transponder;

FIG. 3b illustrates another example of a long and narrow dipole-typetransponder;

FIG. 3c illustrates another example of a long and narrow dipole-typetransponder;

FIG. 3d illustrates another example of a long and narrow dipole-typetransponder;

FIG. 3e illustrates an example of a large two port IC dipole-typetransponder;

FIG. 3f illustrates another example of a large two port IC dipole-typetransponder;

FIG. 4a illustrates an example of a small loop-type transponder;

FIG. 4b illustrates another example of a small loop-type transponder;

FIG. 4c illustrates another example of a small loop-type transponder;

FIG. 4d illustrates another example of a small dipole-type transponderwith an impedance matching loop;

FIG. 4e illustrates another example of a small dipole-type transponderwith an impedance matching loop;

FIG. 4f illustrates yet another example of a small dipole-typetransponder with an impedance matching loop;

FIG. 5 is a simplified top view of a co-centered long and narrowdipole-type transponder and an encoding element in a center-justifiedlabel positioning printer system;

FIG. 6 is a simplified top view of a co-centered small loop-typetransponder and an encoding element in an edge-justified labelpositioning printer system;

FIG. 7a is a top view of an encoding element consistent with anotherexemplary embodiment;

FIG. 7b is the view of FIG. 7a with the shield and the top dielectricsubstrate not illustrated in order to make the conductive strip 762visible;

FIG. 8a is a top view of an encoding element consistent with yet anotherexemplary embodiment;

FIG. 8b is the view of FIG. 8a with the shield and the top dielectricsubstrate not illustrated in order to make the conductive strip 862visible;

FIG. 9 is a top view of an encoding element in a printer-encoderconsistent with an exemplary embodiment comprising a conductive striphaving two non-concentric loop shapes;

FIG. 10 is a top view of a first encoding element in combination with asecond encoding element based on a microstrip transmission line (TL)according to exemplary embodiment;

FIG. 11A is a top view of a first encoding element in combination with asecond encoding element based on a coplanar wave guide (CWG) accordingto another exemplary embodiment;

FIG. 11B is a top view and a side view of a CWG encoding element thatshows the electro-magnetic flux lines created when the CWG encodingelement is active;

FIG. 11C is an isometric view of a CWG encoding element and transponderthat shows the electro-magnetic flux lines created when the CWG encodingelement is active;

FIG. 12 is a top schematic view of an encoding module according to anembodiment;

FIG. 13 is a side schematic view of the encoding module of FIG. 12

FIG. 14a is the encoding module of FIG. 12 with a first type of mediaunits and transponders that are edge-justified;

FIG. 14b is the encoding module of FIG. 12 with a second type of mediaunits and transponders that are center-right-justified;

FIG. 14c is the encoding module of FIG. 12 with a third type of mediaunits and transponders that are center-justified

FIG. 15A is a flow chart of a method according to an embodiment;

FIGS. 15B-15F are top views of an encoding module and media withembedded transponder in various stages of executing the method of FIG.15A;

FIG. 15G is a table that shows the raw data the encoding module receivesfrom a transponder during the calibration method of FIG. 15A;

FIG. 16 is a top view of an access card according to an embodiment;

FIG. 17 is a top view of an encoding module according to an embodiment;

FIG. 18 is a side schematic view of an access control system accordingto an embodiment;

FIG. 19a is a top schematic view of an encoding module according to anembodiment;

FIG. 19b is a top schematic view of an encoding module according toanother embodiment;

FIG. 19c is a top schematic view of an encoding module according to yetanother embodiment;

FIG. 20a is a side view of a coupling device according to an embodiment;

FIG. 20b is a side view of a coupling device according to anotherembodiment;

FIG. 20c is a side view of a coupling device according to yet anotherembodiment;

FIG. 21 is a schematic view a printer-encoder and the coupling device ofFIG. 20b ; and

FIG. 22 is a flow chart of a method according to embodiments configuredto implement the smart sweep functionality.

DETAILED DESCRIPTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout andembodiments discussed herein can be combined with other embodimentsand/or utilize features thereof.

RFID Printer-Encoder

Embodiments of the present invention concern an apparatus for enablingan RFID reader to selectively communicate with a targeted transponderthat is commingled among or positioned in proximity to multiple adjacenttransponders. As will be apparent to one of ordinary skill in the art,various embodiments of the present invention are described below thatselectively communicate with a targeted transponder requiring little tono electro-magnetic isolation of the transponder through the use ofspace-consuming shielded housings, anechoic chambers, anti-collisionprotocols, or relatively more complex or costly collision managementtechniques, although this invention does not preclude their use.

Several embodiments of the present invention may be useful for counting,reading, writing, or otherwise encoding passive or active transpondersattached to items located on assembly lines, in inventory managementcenters where on-demand RFID labeling may be needed, or in other similarcircumstances, where the transponders are in close proximity to eachother. In various embodiments, one or more transponders are mounted toor embedded within a label, ticket, card, or other media form that maybe carried on a liner or carrier. In alternate linerless embodiments, aliner or carrier may not be needed. Such RFID enabled labels, tickets,tags, and other media forms are referred to collectively herein as“media units” or as “smart media units.” As will be apparent to one ofordinary skill in the art, it may be desirable to print indicia such astext, numbers, barcodes, graphics, etc., to such media units before,after, or during communications with the transponders.

An example of an RFID system that may benefit from one or more of theembodiments of the present invention is a RFID enabled printer system,also referred to herein as “printer-encoder” or a RFID print-engineapplicators. Examples of printer-encoders are disclosed incommonly-owned U.S. Pat. Nos. 6,481,907; 6,848,616; and 7,398,054 whichare hereby incorporated herein by reference in their entirety.

FIG. 1 illustrates an example of a RFID printer-encoder 120 structuredfor printing and encoding a series or stream of media units 124. Theprinter-encoder 120 includes several components, such as a printhead128, a platen roller 129, a feed path 130, a peeler bar 132, a mediaexit path 134, rollers 136, a carrier exit path 138, a ribbon take-upspool 140, a ribbon supply roll 141, a reader 142, a controller 145, andan encoding element 150 (also sometimes referred to herein as a“coupling device”).

As noted above, media units may include labels, cards, etc., that arecarried by web 122, which may be, e.g., a substrate liner. The web 122is directed along the feed path 130 and between the printhead 128 andthe platen roller 129 for printing indicia onto the media units 124. Theribbon supply roll 141 provides a thermal ribbon (not shown for clarity)that extends along a path such that a portion of the ribbon ispositioned between the printhead 128 and the media units 124. Theprinthead 128 heats up and presses a portion of the ribbon onto themedia units 124 to print indicia. The take-up spool 140 is configured toreceive and spool the used ribbon. This printing technique is commonlyreferred to as thermal transfer printing. However, several otherprinting techniques may be used including, but not limited to, directthermal printing, inkjet printing, dot matrix printing, andelectro-photographic printing.

After printing, the media unit web 122 proceeds to the media exit path134 where the media units are typically individually removed from theweb 122. For example, in one embodiment, pre-cut media units 124 may besimply peeled from the web 122 using the peeler bar 132 as shown. Inother embodiments, a group of multiple media units may be printedtogether and transmitted downstream to an in-line cutter for subsequentseparation (not shown). Various other known media unit removaltechniques may be used as will be apparent to one of ordinary skill inthe art.

In applications, such as the depicted embodiment, in which the mediaunits 124 are supported by a web 122, the web 122 may be guided along apath toward the carrier exit path 138 by rollers 136 or other devicesafter being separated from the media units. Structures that performtechniques for conveying or guiding the web of media units along theentire feed path of the printer-encoder are sometimes referred to hereinas conveyance systems. The reader 142 is configured to generate andtransmit RF communication signals that are broadcasted by the encodingelement 150 located proximate the media feed path 130. For purposes ofthe present specification, the reader 142 and the encoding element 150may be referred to collectively as forming at least part of acommunication system. As will be explained in more detail below, thecommunication system can be configured to transmit one or moreelectromagnetic waves for establishing a mutual coupling, such as awireless communications path, between the reader and a targetedtransponder of a media unit that is located in the transponder encodingarea, such that data may be read from and/or written to the media'stransponder. As such, reader 142 can be used as a means for transformingelectrical signals into wireless electromagnetic signals, which can beused to program a media's transponder(s) with computer readable data,similar to how a conventional printhead is used to transform electricalsignals into printed words that are human-readable. Reader 142 can alsobe used as a means for reading data stored in the media'stransponder(s), similar to how a bar code reader or scanner is able totransform barcodes printed on media into electrical signals and theninterpret the meaning of electrical signals.

Each electromagnetic wave (used to, e.g., establish the mutual coupling)has different signal strengths depending on the distance from theencoding element. The strength in the near-field usually differs fromthe strength of the far-field. In general, the far-field of the encodingelement is often too weak to activate or communicate with any of thetransponders, while the near-field of the encoding element is usuallystrong enough in the transponder encoding area such that it onlyactivates the media's transponder in the transponder encoding area.

In general, the reader is a device configured to generate, receive andprocess electrical communication signals. One skilled in the art wouldappreciate that similar devices, including various transmitters,receivers, or transmitter-receivers, may be used within embodiments ofthis invention. “Reader” as used herein refers to the devices notedabove and to any other device capable of generating, processing, orreceiving electrical and/or electromagnetic signals. For example, areader may be a combination of a receiver and a transmitter.

Encoding Element

FIGS. 2a and 2b illustrate an exemplary embodiment of the encodingelement 150. According to this embodiment, the encoding element 150 isbased on a terminated uniform stripline transmission line that forms aloop. The encoding element 150 has a layered structure comprising afirst conductive layer 254 (sometimes referred to herein as the groundlayer 254), a first dielectric substrate 256, a conductive strip 252, asecond dielectric substrate 258, and a shield 260. Together theconductive strip 252 and the ground layer 254 (which may have aco-centered hole) define a transmission line 255.

More specifically, according to the illustrated embodiment of FIGS. 2aand 2b , the ground layer 254 has a first surface and a second surface.The first dielectric substrate 256 has a first surface and a secondsurface. The first surface of the first dielectric substrate 256 isadjacent to the second surface of the ground layer 254. The conductivestrip 252 also has a first surface and a second surface. The firstsurface of the conductive strip 252 is adjacent to the second surface ofthe first dielectric substrate 256. The second dielectric substrate 258has a first surface and a second surface. The first surface of thesecond dielectric substrate 258 faces the second surface of the firstdielectric substrate 256 and is adjacent to the second surface of theconductive strip 252. The shield 260 has a first surface and a secondsurface. The first surface of the shield 260 faces and is adjacent tothe second surface of the second dielectric substrate 258.

As best seen on FIG. 2a , according to this embodiment, the shield has ageneral split-ring shape that generally corresponds to the portion ofthe conductive strip 252 shaped as a loop. For example, the shape andthe positioning of the shield 260 is such that the portion of theconductive strip 252 shaped like a loop extends directly between theshield 260 and the ground layer 254 and the portion of the conductivestrip 252 shaped like a loop and the shield 260 are generallyconcentric. The portion of the conductive strip 252 shaped like a loopmay extend generally underneath (or above, depending on the orientationof the encoding element 150) a centerline of the shield 260. The shield260 may be connected to the ground layer 254 through one or moreconnections. For example, in the illustrated embodiment of FIGS. 2a and2b , the encoding element 150 includes a plurality of vias 266 extendingalong the inner and outer edges of the shield 260 to the ground layer254. As shown, the shield 260 provides a central open area 261 intendedto facilitate the propagation of the magnetic fields from the conductivestrip 252 at the center of the encoding element 150. Moreover, theplacement of the shield 260 helps to suppress the electric field abovethe conductive strip 252 while being transparent for the magnetic field.Also, the shield 260 helps to protect the encoding element 150 fromexternal electric field interferences.

The dielectric substrates 256, 258 may be made or constructed fromvarious dielectric materials, including but not limited to, plastics,glasses, ceramics, or combinations such as Rogers materials, Isolamaterials, or woven glass reinforced epoxy laminate, such as thosecommonly referred to as “FR4” or flame resistant 4. As another example,the dielectric material may be air. Therefore the ground layer 254 andthe shield 260 may be spaced apart from each other and have only air andthe conductive strip 252 between them. One skilled in the art wouldappreciate that these various materials may be used to achieve anappropriate transmission line 255 characteristic impedance for aspecific dielectric constant.

As explained in more detail below, the transmission line 255 provides aconductive plane for the propagation of electromagnetic waves from theencoding element 150 to a targeted transponder (not shown in FIG. 2A or2B). As examples, the conductive material of the conductive strip 252and the ground layer 254 may be copper, gold, silver, aluminum orcombination thereof, or doped silicon or germanium. The conductive strip252 extends from a first end 262 to a second end 264. As mentioned, theconductive strip 252 forms a loop like shape. The length of theconductive strip 252 is defined by the distance from the first end alongthe conductive strip 252 to the second end. The ground layer 254 mayhave various shapes. For example, the ground layer 254 may be generallyrectangular and correspond to the overall shape of the encoding elementor follow the shape of the conductive strip.

The methods of fabricating the encoding element(s), including thetransmission line(s) 255 may vary. For example, the dielectric substratemay include a cut out area where the area above the cut out is the firstdielectric substrate and the area below the cut out is the seconddielectric substrate. In this type of embodiment, the conductive strip252 may be inserted into the cut out area such that it is between thefirst and second dielectric substrates 256, 258. As another example, theconductive strip 252 may be deposited directly (e.g., printed or etched)onto either the second surface of the first dielectric substrate 256 orthe first surface of the second dielectric substrate 258.

The first end 262 of each conductive strip is connected to an input andoutput port 268 of the encoding element. The second end 264 is connectedto a terminating load 270 of the encoding element. The terminating load270 may be equal to a system impedance. The input and output port 268connects the reader to the encoding element. For example, each inputport and output port may be a radio frequency port (“RF port”). Inparticular, the reader can be configured to send an electrical signal tothe encoding element through the input and output port 268. The signalpasses through the input and output port 268, the conductive strip 252,and into the terminating load 270, which is connected to the groundlayer 254 or is otherwise grounded.

As the electrical signal passes through the transmission line 255, thetransmission line 255 does not operate as a conventional radiatingantenna. But rather the passing signal in the transmission line 255generates magnetic fields concentrated in the near field region of thetransmission line 255. The magnetic fields may be adapted to couple thereader (through the encoding element 150) to a transponder disposedproximate the encoding element 150, referred to herein as thetransponder encoding area. Additional examples of the magnetic fluxgenerated by encoding elements are show in and discussed in connectionwith FIGS. 11B and 11C. Further description of the magnetic and electricfields concentrated in the near field region, also known as “leaky”electromagnetic fields, is provided in commonly owned U.S. patentapplication Ser. No. 12/463,841, U.S. Patent Application PublicationNos. 2007/0262873 and 2007/0216591 U.S. Pat. No. 7,398,054 to Tsirlineet al., which are each hereby incorporated by reference in its entirety.

According to another embodiment, the characteristic impedance of thetransmission line 255 may be configured to be equal to the terminatingload and the system impedance. In such an embodiment, the RF portimpedance equals the terminating load 270 and the system impedance,e.g., 50 ohms, independent from the length of the transmission line andallows for the widest possible bandwidth. The RF port may also have astanding wave ratio of less than or equal to 2 (i.e., VSWR≦2) in a widefrequency band covering spectrum requirements for RFID applications invarious jurisdictions (e.g., in EU, U.S. and JP, which is 860-960 MHz).Moreover, in such an embodiment, the magnetic field strength is evenlydistributed along the length of the transmission line.

U.S. Patent Application Publication Nos. 2007/0262873 and 2007/0216591and U.S. Pat. No. 7,398,054 to Tsirline et al. disclose among otherthings, using a microstrip or stripline linear transmission line orlines as a near-field antenna. Although near-field antennas based on alinear microstrip or a stripline transmission line may be adequate forthe encoding of certain types of media units within certain types ofprinter-encoders, such near-field antennas may have limitations.

More specifically, FIGS. 3a through 3f illustrate examples of a firstcategory of transponders referred to as long and narrow or largedipole-type transponders due to the structure of the antennas of thetransponders. FIGS. 4a through 4f illustrate examples of a secondcategory of transponders referred to as an item-level or a smallloop-type transponder due to the structure of the antennas of thetransponders. Terms such as “long and narrow”, “large” and “small” asused herein are intended to indicate the relative size of thetransponders compared to an operational wavelength of the transponder orcompared to its relative dimensions. As examples, the large dipole-typemay be about 3 inches long (i.e., the largest dimension of thedipole-type) and may be about 0.3-0.6 inches wide and the smallloop-type may be about 1 inch long and 1 inch wide.

In many systems, a near-field antenna, as an electric field exciter,based on a microstrip or stripline transmission line is generally placedcross-wise relative to the feeding path or feeding direction, such thatlength of the active conductive strip of the near-field antenna isorthogonal to the feeding path or feeding direction. The alignment ofthe media units within the printer-encoder may be referred to as eitheredge-justified (also sometimes referred to as side-justified) orcenter-justified. In an edge-justified system, the media unit ispositioned near or aligned with one of the ends of the conductive stripof the near-field antenna regardless of the relative sizes of the mediaunit and the near-field antenna. In a center justified system, the mediaunit is positioned proximate to the center of the conductive strip ofthe near-field antenna regardless of the relative sizes of the mediaunit and the near-field antenna. Typically, the transponder of the mediaunit is centered relative to the media unit. Therefore the alignment ofthe media unit to the antenna may also coincide with the alignment ofthe transponder to the transponder. As examples, the width of the mediaunit may be 1″, 1.5″, 2″, 3″, 4″, or more.

In general, microstrip and stripline electric field source antennas havea limited RF power efficiency because their electric field distributionis concentrated between the conductive strip and the ground planes, andthe field strength above the conductive strip is relatively weak. Whenthe characteristic impedance of the microstrip or stripline is lowerthan a terminating load then the maximum strength of the magnetic fieldcomponent emitting from the conductive strip of a stripline ormicrostrip near-field antenna is at the center of the conductive stripand the maximum strength of the electric field component emitting fromthe conductive strip of a stripline or microstrip near-field antenna isat the ends of the conductive strip. When the characteristic impedanceis higher than the terminating load, then the maximum strength of themagnetic field component is at the ends of the conductive strip and themaximum strength of the electrical field component is at the center ofthe conductive strip. The distribution of electric and magnetic fieldcomponents for microstrip and stripline transmission lines is furtherdiscussed in detail in “UHF RFID Antennas for Printer-Encoders-Part 1:System Requirements”, High Frequency Electronics, Vol. 6, No. 9,September 2007, pp. 28-39 which is authored by one of the inventors ofthe present application and is hereby incorporated by reference in itsentirety.

Therefore, in a center-justified system processing large dipole-typetransponders, the electric and magnetic field components from thenear-field antenna can be configured to be optimally aligned with thecenter of the transponder to facilitate reliable communication betweenthe transponder and the reader through the near-field antenna. In someinstances, a large dipole-type transponder may be large enough relativeto the near-field antenna that even in an edge-justified system thetransponder is close enough to the center of the conductive strip not tomake a significant difference in the near-field antenna's ability tocommunicate with the transponder in the edge-justified system comparedto a center-justified system.

However, for small loop type transponders, a linear stripline ormicrostrip near-field antenna may by incapable of providing reliablecommunication with transponders at a desired or acceptable power leveldepending on whether the system is edge justified or center-justified.

In a center-justified system, although relatively small compared to theoperating wavelength of the microstrip near-field antenna, the loop-typetransponder may be generally aligned with the center of the microstripnear-field antenna, where the magnetic field strength is the greatest.Such an alignment allows for reliable communication at an acceptablepower level.

In an edge justified system, the transponder may be off-set from thecenter of the near-field antenna such that communication between thetransponder and the near-field antenna may require relatively higherpower levels because the transponder is not over the area of thenear-field antenna where the magnetic field strength is the greatest(indeed in some cases, the transponder may be over the area of thenear-field antenna where the magnetic field strength is the weakest).Further discussion regarding types of coupling devices or encodingelements, types and placement of transponders and calibrating the sameare provided in the following commonly-owned patents and publishedapplication: U.S. Pat. Nos. 7,398,058, 7,190,270, and 7,489,243 and U.S.Publication Nos. 2005/0274799 and 2009/0008448. Each of the foregoing ishereby incorporated by reference in its entirety.

The embodiment illustrated in FIGS. 2a and 2b may be positioned within aprinter-encoder or other RFID system to communicate with either type oftransponder types. The loop shape of the conductive strip is configuredto create a highly concentrated (e.g., high magnetic flux density (3) atthe center of the conductive strip, i.e., above the central open area261 of the shield. As shown in FIG. 5, in a center-justified system, theencoding element 150 may be positioned within the printer-encoder (i.e.,substantially centered along the feed path) such that it issubstantially aligned with the center of the large-dipole typetransponders 510 as the media units 500 pass over the encoding element150, where a large-dipole type transponder is the most sensitive tomagnetic fields. As shown in FIG. 6, in an edge-justified system, theencoding element 150 may be positioned within the printer-encoder (e.g.,along an edge of the feed path) such that it is substantially alignedwith the center of the small loop-type transponders 610 as the mediaunits 600 pass over the encoding element 150, where a small loop-typetransponder is the most sensitive to magnetic fields.

The center to center alignments in both a center-justified system and inan edge-justified system, allows for reliable communication at anacceptable power level between the reader and the transponder via theencoding element. Acceptable power levels may be determined based on oneor more factors including, but not limited to, the power level availablefrom the reader and regulations or laws limiting maximum power levels.Moreover, rather than focusing on a particular power level, one factorthat may be considered is relative power levels, i.e., whether theencoding element from its position can communicate successfully with thetransponder at a power level compared to other positions or other typesof encoding elements.

In some embodiments, rather than the conductive strip 762 having oneportion shaped as one loop, the encoding element 750 may include aspiral shape 780 (or, more specifically, an Archimedean spiral) such asillustrated in FIGS. 7a and 7b . In yet other embodiments, rather thanhaving a strictly “circular” shape, the loops of the conductive strip862 may be rectangular in shape 880 such as illustrated in FIGS. 8a and8b . In the embodiments having a plurality loop shapes, the encodingelement 750, 850 may include an input port 768, 868, a terminating load770, 870, dielectric substrate(s) 756, 758, 856, 858, a ground plane(not visible in the drawings), and a shield 760, 860 as described abovefor the single loop embodiment.

The embodiments of FIGS. 7a, 7b, 8a and 8b include a plurality of loopshapes that are substantially coplanar and concentric. The embodiment ofthe encoding element 950 illustrated in FIG. 9 includes a conductivestrip 952 shaped to have at least two loop shaped portions 980, 982spaced apart. The two loop shaped portions 980, 982 of the conductivestrip 952 may be coplanar. The first loop shaped portion 980 may bepositioned such that the center of the first loop shaped portion 980 isaligned with the center of a small loop-type transponder that is edgejustified as the small loop-type transponder travels over the encodingelement 950 while the second loop shaped portion 982 may be positionedsuch that the center of the second loop shaped portion 980 is alignedwith the center of a large dipole-type transponder that is centerjustified as the large dipole-type transponder travels over the encodingelement 950. Therefore, the encoding element 950 may be configured tocommunicate with either an edge-justified small loop-type transponder ora center-justified large dipole-type transponder.

FIGS. 10 and 11A-C illustrate other exemplary embodiments. The encodingelement described above may be combined with other types of encodingelements or antenna-couplers using, for example, a cascaded connectionor connections. As an example, FIG. 10 illustrates a first encodingelement 1050 that is a magnetic exciter having the conductive strip 1052that includes a loop-shaped portion 1054 and a second encoding element1090 that is an electric exciter based on a one half wavelength, orother multiple thereof, tapered microstrip 1092. Embodiments of a secondencoding element or antenna coupler 1090 based on the tapered microstrip1092 is further disclosed in U.S. Patent Application Publication No.2007/0216591, which as stated above is incorporated by reference. In theembodiment illustrated in FIG. 10, the combination of the first encodingelement 1050 and second encoding element 1090 includes an RF port 1068in communication with a first end 1062 of the conductive strip 1052 ofthe first encoding element. The second end 1064 of the conductive strip1051 of the first encoding element is in communication with a first end1094 of the tapered microstrip 1092 of the second encoding element. Thecombination further includes a terminating load 1070 in connection witha second end 1095 of the tapered microstrip. As an example, thisparticular combination enables encoding of media units having thefollowing widths 1″, 3″, and 4″ media units.

As another example, FIG. 11A illustrates a combination of a firstencoding element 1150 that is a magnetic exciter having the conductivestrip 1152 that includes a loop-shaped portion 1154 and a secondencoding element 1190 that is an electric exciter. As a more specificexample, the second encoding element may be a coplanar wave guide. Acoplanar wave guide includes a conductive strip 1192 and two groundplanes 1196, 1197 and is further disclosed in commonly owned U.S. patentapplication publication number US2009/0152353, entitled “RFID Near-FieldAntenna and Associated Systems” and filed on Dec. 18, 2007 to Tsirlineet al., which is hereby incorporated by reference in its entirety. Inthe embodiment illustrated in FIG. 11A, the combination of the first andsecond encoding elements 1150, 1190 includes an input RF port 1168 incommunication with a first end 1162 (e.g., the input end) of theconductive strip 1152 of the first encoding element. A second end 1164(e.g., the loaded end) of the conductive strip 1152 of the firstencoding element is in communication with a first end 1194 (e.g., theinput end) of the coplanar waveguide 1190. The combination furtherincludes a terminating load 1170 in connection with a second end 1195(e.g., the loaded end) of the coplanar waveguide 1190. As an example,this particular combination enables encoding of media units having thefollowing widths: 1″, 2″, 3″ and 4″.

The above embodiments relate to a coupler device having a terminatedloop shape portion which differs from conventional loop antennas. Forexample, the above embodiments are terminated with a terminating loadwhile conventional loop antennas for UHF and above frequency bands areopen-ended. As another example, the above embodiments provide for mainlymagnetic coupling with transponders, e.g., UHF transponders, and have arelatively low susceptibility to a metal-dielectric environment ofprinter-encoders or other similar systems. Conventional UHF loopantennas rely mainly on close proximity electro-magnetic coupling with atransponder and are more susceptible to a metal-dielectric environment.

Common to both FIGS. 10 and 11A, a transmission line (second encodingelement 1090 of FIG. 10 and second encoding element 1190 of FIG. 11A),is terminated at one end by the terminating load 1070 and 1170,respectively. The terminating load 1070, 1170 may be configured for RFport impedance matching. For example, loop type couplers, example ofwhich are first encoding element 1050 of FIG. 10 and first encodingelement 1150 of FIG. 11A, can have a characteristic impedance equal tosystem impedance of the second encoding element, load impedance, andreader RF port impedance. At the center operating frequency, the inputimpedance of first encoding element 1050, 1150 at a first end of atransmission line of second encoding element 1090, 1190 that has alength (i.e., measured from the first end to a second end of secondencoding element 1090 or 1190) of one half wavelength, or a multiplethereof, is substantially equal to the terminating load 1070, 1170,regardless of the characteristic impedance of the transmission line ofsecond encoding element 1090, 1190. Therefore, in some embodiments, thelength of the transmission line of second encoding element 1090, 1190may be one half wavelength, or multiple thereof (i.e., the length maysubstantially equal N*λ/2, wherein N may equal 1, 2, 3, 4, 5, . . . )and the terminating load 1070, 1170 may be configured to match thesource impedance in order to substantially match the source impedanceand/or the input impedance.

Although the relationship between the characteristic impedance of thetransmission line of second encoding element 1090 or 1190 and theterminating load 1070, 1170 impedance may vary, according to anembodiment, the characteristic impedance distribution may be configuredto maximize the magnetic field at the center of the conductive strip offirst encoding element 1050, 1150. Further, terminating the transmissionline of second encoding element 1090 or 1190 with a terminating load1070, 1170 that is substantially equal to the source impedance andgreater or lower than the characteristic impedance of the transmissionline of second encoding element 1090 or 1190 forms a band-pass filter.

In some embodiments, the characteristic impedance of the transmissionline of second encoding element 1090 or 1190 may be principally equal tothe impedance of the reader and the terminating load 1070, 1170 thus theencoding element may have a wide bandwidth and capability of toleratingmechanical and electrical parameter deviations. In conventional loopantennas, such as first encoding element 1050, 1150, typically amismatched port impedance exists or requires a matching network and/ornarrow bandwidth. Above embodiments may comprise a shield. The shieldcan function as one of the two ground layers of the modified striplinetransmission line, which decreases parasitic radiations and istransparent to a magnetic field.

Generally, conventional loop antennas are open, highly radiationefficient, and have non-localized fields and consequentially have nospatial selectively to communicate with a targeted transponderpositioned among a group of multiple adjacent transponders. Embodimentsof the resonant loop encoding element, such as in HF (e.g., at or about13.56 MHz) and lower systems, may be arranged in parallel andco-centered alignment with a targeted transponder to provide high mutualinductance and coupling, highly localized magnetic flux to or around thetargeted transponder while the coupling effect (e.g., grade, depth,etc.) with adjacent transponders is significantly lowered. When creatinga matrix structure for a HF encoding module, the encoding elements cancomprise resonant circuits formed by a coil (or traces on PCB),frequency tuning and impedance matching capacitors, and resistors, someexamples of which are discussed in commonly-assigned U.S. PatentApplication Publication No. 2008/0298822, filed May 30, 2007, No.2008/0298870, filed May 30, 2007, No. 2008/0117027, filed Nov. 16, 2007,and U.S. Pat. No. 7,137,000, filed Jun. 6, 2002, which are incorporatedherein by reference in their entireties. Therefore this arrangement andencoding element may provide both high spatial selectivity and high RFpower margin inside a transponder encoding region in which the powerdelivered to a targeted transponder exceeds an activation powerthreshold of the targeted transponder. In addition, the power deliveredto the transponders located outside the transponder encoding region canbe less then the activation power threshold of adjacent transponders.These features in a conventional UHF loop antenna are lacking. Ingeneral, to limit an encoding range, a conventional loop antenna shouldbe weakly coupled with the targeted transponder and/or be fed by reducedRF power from the reader. The former referenced approach dictates anincrease of RF power that in turn creates an issue of communicating withmultiple adjacent transponders at once. The latter referenced approachruns the risk of lower encoding yield, because an RFID system has a lowpower margin and is unable to compensate for the negative effect(s) ofan antenna and variables associated with the transponders electricalparameters.

Further to the discussions related to FIGS. 11A, 2A and 2B, FIGS. 11Band 11C show the magnetic flux generated by a UHF CWG encoding elementthat magnetically couples to a transponder. As shown in FIGS. 11B and11C, there is maximum sensitivity to magnetic fields at the center ofthe encoding element's loop. Many UHF encoding elements, regardless ofwhether they are dipole or loop type, have an impedance matching elementbetween the antenna and the integrated circuit. The impedance matchingelement (as discussed elsewhere herein) is often a conductive loop,which allows for magnetic coupling between the closely spacedtransponder and antenna of the Reader's UHF RFID coupling element. Evenwhen a dipole type's antenna is directly attached to the integratedcircuit, the maximum sensitivity to a magnetic field is at its center.In RFID applications (e.g., RFID printer-encoders, access controlsystems, item-level RFID conveyor tracking systems, etc.) where the UHFtransponder's antenna is in close proximity to the encoding element, thecharacteristics of the electrical coupling is similar to those of HFRFID magnetically coupled devices.

To create a miniature magnetic encoding element, a coplanar waveguide(CWG) can be banded to form a loop (as discussed above and shown inFIGS. 11B and C). The shape of the look can assume different profiles(as discussed above in connection with, e.g., FIGS. 2-3) and be, forexample, a square loop, a rectangular loop, an elliptical loop, etc. Theloop's characteristic impedance can be configured to be equal to thetermination load's impedance (as shown in FIG. 11B) and the system'simpedance, which can be 50 ohms. Accordingly, the magnetic fieldgenerated by the CWG encoding element can be evenly distributed. The RFport can have a VSWR≦2 in a wide frequency band that can cover spectrumrequirements for RFID applications in the European Union, United Statesand Japan (e.g., 800-960 MHz). FIG. 11C shows how a loop CWG encodingelement can generate magnetic flux that intersects a transponder's looparea and achieve maximum strength when in co-centered alignment.Accordingly, the enabling element can be configured so that magneticflux falls intensively in response to the co-centered alignment beingskewed, thus allowing the system to maintain a high spatial selectivitywhen working with a plurality of adjacent transponders.

Encoding Module

In some embodiments, such as portable and compact printer-encoders orother systems, the encoding element may be near or approximate with theprintline, i.e., the first point along the feed path in which theprinthead is configured and positioned to print on the media unit. Forexample, the encoding element may be close enough to the printline thatat least a part of the communication area for some types of transpondersoverlaps the printline, which may allow the system to encode theshortest possible labels or maintain the shortest pitch between labels.In other words, the system may be configured such that the system isprinting indicia onto the media unit while it is interrogating orencoding the transponder of the same media unit. The close proximity ofthe encoding element and printhead may be necessary or desirable inorder to maintain overall compact design of the system. It may alsocreate a situation in which the interrogation or encoding of atransponder occurs in essentially the same space as any printingoperations.

The minimum distance from the printline to the leading edge of aparticular transponder, such as a targeted transponder, when theencoding element is able to communicate with that transponder isreferred to herein as the “starting encoding distance.” The distancefrom the starting encoding distance to the downstream point in which theencoding element is unable to communicate with the transponder isreferred to herein as the “encoding range.” It is believed that thestarting encoding distance is defined by the characteristics of thetransponder, such as its antenna, and the characteristics of thestructure and components of the system near the printline, such as theplaten roller and the printhead and that the encoding range is definedby the characteristics of the transponder and the encoding element.

As examples, the platen roller, the printhead, and other components mayimpact coupling between the transponder and the encoding element nearthe printline. More specifically, in some systems, along the feed pathin which the metal-dielectric environment of the platen roller, theprinthead, and other components prevents or otherwise interferes withcommunications between transponder and the reader.

The starting encoding distance may vary depending on the type oftransponder being encoded. Also, as discussed above, in addition to thetype of transponder, the relative location of the transponder on themedia unit may vary. The encoding element may be specifically configuredto have a limited range to selectively activate and providecommunication with one transponder at a time. For example, according tothe embodiment of FIGS. 2a and 3b , the encoding element is generallyconfigured to activate and provide communication with a co-centeredtransponder directly above it (or below depending on the relativeorientation of the system). This may be accomplished by configuring theencoding element to generate a magnetic flux that intersects atransponder's loop area, thereby achieving a maximum level forco-centered alignment. This flux intensively falls as soon as atransponder's loop is skewed from a center of the coupling element, thusmaintaining a high spatial selectivity in relation to adjacenttransponders. Therefore, the optimal location of the encoding elementalong the feed path may vary depending on the type and placement oftransponder(s). See, e.g., FIGS. 11B and 11C above for additionalexamples and details regarding achieving a maximum level of magneticflux through co-centered alignment of the encoding element andtransponder.

However, it is typical that the encoding element or the coupling deviceof the system, such as a printer-encoder, is installed into theprinter-encoder by the manufacturer or assembler prior to the loadingand encoding of the transponders. Therefore, it is possible that theencoding element of the coupling device of the printer-encoder is in aless-than-optimal or unacceptable position to enable it to couple thereader and the transponder depending on the type and placement of thetransponder. Also, some customers prefer to use the printer-encoder toprocess various types of media units that have different types andplacement of the transponders.

Commonly-owned U.S. patent application Ser. No. 12/463,841 (“the '841application) filed on May 11, 2009 to Tsirline et al., the entirety ofwhich is hereby incorporated by reference, addresses this challenge byproviding a multi-element coupling device in which the elements can beselectively connected or combined in order to adjust the distribution ofan electromagnetic filed along the elements based on the type andplacement of the transponder to be processed. Embodiments herein alsomay also address the same issue in addition to or rather than theapproach disclosed in the '841 application.

For example, according to an embodiment, such as the embodimentillustrated in FIGS. 12-13, an encoding module 1200 is provided that isconfigured to adjust to the type and location of the transponder on themedia unit. The encoding module 1200 may include a plurality of encodingelements or elements 1210 forming an array. As discussed above, eachencoding element 1210 may be configured to have a limited range suchthat each encoding element can selectively activate and communicativewith one transponder at a time. As an example, each of the encodingelements of the encoding module for UHF band may be any of the encodingelements illustrated in FIGS. 2A-B and 7A-8B. As another example, eachof the encoding elements of the encoding module for LF band may be aresonant multi-coil (loop) antenna tuned to an operational frequency andmatched to the system impedance, such as 50 ohms. The encoding module1200 may further include one or more switching elements 1220 (e.g.,mechanical switches, transistors, PiN diodes, among other things). Theswitching elements 1220 are configured to selectively connect theencoding elements 1210 with the reader 1230. The term “connected” or“connect” as used herein refers to an encoding element beingelectrically coupled to the reader such that the encoding elementprovides unidirectional or bidirectional communication between thereader and the transponder.

During operations, the switching elements 1220 may be used toselectively connect an encoding element or devices to the reader. Morespecifically, a column and a row of encoding elements may be selected.As illustrated in FIG. 12, the plurality of encoding elements 1210(e.g., A1, A2, A3, A4, B1, B2, . . . ) may be arranged in an arraycomprising a plurality of columns and rows. Each column (1, 2, 3, 4) mayextend parallel to the feed path (i.e., be longitudinal relative to thefeed path) and each row (A, B, C, D) may extend perpendicular to thefeed path (i.e., be crosswise with respect to the feed path).

The selection of the encoding element (e.g., the column and rowselection) may be based on, for example, the type and dimensions of thetransponder, the placement of the transponder on the media unit, thelocation of the media unit in the system (e.g., edged or centeredjustified), the metal-dielectric environment within the system, amongother things.

The column 1, 2, 3, 4 of encoding elements 1210 of the encoding module1200 may be selected based on the location of the transponder relativeto the edges or center of the feed path. For example, an encodingelement 1210 of the innermost column 1 may be selected if thetransponder 1400 is located over the innermost column, e.g., asillustrated in FIG. 14a . Similarly, an encoding element 1210 of acenter column 2, 3 or the outmost column 4 may be selected if thetransponder 1400 is located over or centered on one of those columns,e.g., as illustrated in FIGS. 14b and 14 c.

As discussed above, the inventors' tests suggest that it is optimal, interms of shortest media unit back feed, to encode the transponder asclose to the printline (represented by the platen roller 1215 in FIGS.12 through 14 c), as possible. Therefore, each row of encoding elementsA, B, C, D may be selected to provide for the shortest starting encodingdistance. Also as discussed above, the printer structure and the typeand dimensions of the transponder may impact the distances and ranges inwhich communication with the transponder is possible or reliable.Therefore, the selected row may vary depending on the components of theprinter and the type and dimensions of the transponder.

The switching elements 1220 may be controlled by a processor 1250 (e.g.,a software, firmware and/or hardware configured processor, which mayinclude a field programmable gate array (FPGA)), a controller, othercombinational logic or the like. In this regard, the processor may beconfigured to retrieve and execute program instructions stored on acomputer-readable storage medium for controlling the switching devices1220.

As another example, according to an embodiment, the processor 1250 maybe configured to execute a calibration method for determining theplacement (or location) of the transponder on the media unit ordetermining the optimal encoding element to connect for the transponder.The calibration method may take place automatically (e.g., in responseto the system determining that it needs to be calibrated for aparticular type of media, due to the lapsing of time, etc.) or inresponse to receiving a user input associated with the starting of atransponder calibration. In some embodiments, the calibration processwill result in the choosing of a RF program position where the leadingedge of the media is placed optimally at the print line. In otherembodiments, the calibration process will result in determining themidpoint of the longest write streak of the media.

As illustrated in FIGS. 15A-G, the method, at block 1510 of FIG. 15A,may include moving a media 1502 having backing 1504 and an embeddedtransponder 1400 (as shown in FIG. 15B) to a first position relative toencoding elements 1210 (as shown in FIG. 15C). In some embodiments, theoperator may need to confirm there is at least one inch of media backing1504 outside the system (as shown in FIGS. 15C-15F), which may helpallow for the back feeding of the media inlay while helping to preventthe media from falling off the platen in the reverse direction. At leastone inch of media backing 1504 outside the system can also help ensurethere are no transponders in the “dead zone.” (As referred to herein,the dead zone is an area near the print head where a transponder may beunable to be coupled with an encoding element, largely due to thephysical distance usually required due to the potential detuning of atransponder in some embodiments.) The method may comprise moving theleading edge of the media away from the print line by, e.g., 20 mm, asshown in FIG. 15D, to further help ensure there is no transponder in thedead zone. Then, at block 1520 of FIG. 15A, the method can includeattempting to communicate with the transponder, in a scanning fashion,through at least one or more of the plurality of encoding elements 1210.

Next, at block 1530 of FIG. 15A, the method can comprise determining thelocation of the transponder on the media unit, by activating one or moreencoding elements 1210 in any manner (e.g., from front to back, back tofront, diagonally, etc.). The first position may be at or near the printline as shown in FIG. 15C. The communication attempts may includeattempting to communicate with the transponder 1400 with each of theencoding elements in the array 1210. The attempts may include at leastone attempt per encoding element. For example, attempts may be made foreach encoding element through a range of acceptable power levels or at apredetermined power level (such as, e.g., at or near 22 dBm). Thedetermination of the location of the transponder on the media unit(e.g., the location of the transponder relative to a front edge or sideedge of the media unit) may be based on the locations (i.e., the row andcolumn) of the encoding elements in which the communication attemptswith the transponder were successful and the power levels at which thecommunication attempts were successful.

Rather than or in addition to determining the relative placement of thetransponder 1400 on the media unit 1500, the method may includeidentifying the optimal encoding element at block 1540 to communicatewith the transponder 1400 or, more specifically, for that particulartype of transponder on that particular type of media unit. Thedetermination of the optimal encoding element may be based on theencoding element or devices capable of ensuring a reliable encodingprocess at the lowest power level and the encoding element or devicesclosest to the printline or other through-put considerations. Theoptimal criteria may further include selecting a preferred or most-oftenused location, such as a preferred column or row, in order to identify asingle encoding element as the optimal encoding element rather thanidentify more than one optimal encoding element “candidates.” Forexample, in FIG. 15E, encoding elements B2, B3, C2 and C3 can become thecandidates. In some embodiments, such as when the testing occurs fromfront to back and the transponder is detected near the front, time canpotentially be saved by stopping once the candidates have beenidentified. A “reliable encoding process” may be defined as the abilityof the printer-encoder or other system to activate the targetedtransponder regardless of its parameter deviations within the samegroup, and communicate with the targeted transponder through theencoding element while minimizing inadvertent activation of untargetedtransponders.

In some embodiments, the candidates represent one or more columns ofencoding elements, such as columns 2 and 3 of FIG. 15E, that need to befurther evaluated. In such embodiments, the system can continuously testthe first row (e.g., the “A” row) to profile the transponderperformance. FIG. 15E show various representations of readings taken bythe encoding elements in the closest proximity to the transponder. Thetesting, like the other calibration testing discussed herein, cancomprise taking readings every mm of movement, while the media (and thetransponder) moves forward until the calibration is complete for eachcandidate. Next, while an optimal encoding element has yet to beconfirmed and the leading edge of the media is within a predetermineddistance to the printline (e.g., 3 mm or any other distance that givesthe desired tolerance to choose the most robust encoding position) asshown in FIG. 15F, the system can begin testing other encoding elements(which may be in the same column) that can be used to successfullyencode the transponder when the media is at the printline. Once enoughdata is collected as shown in FIG. 15G, a determination is made as towhat is the optimal encoding element (as discussed in the precedingparagraph). The criteria for selecting the optimal encoding element canbe based on, for example, the encoding element that is positioned toenable encoding at the printline where there is also a buffer ofencoding success. The buffer can be a comprised of preconfigureddistance (e.g., 2 mm) on either side or can be variable based on thesize of the encoding elements, transponder, etc. As another example, thecriteria for selecting the optimal encoding element can comprise theencoding element positioned in a manner where there is a buffer but isunrelated to the location of the printline.

Once the optimal encoding element is determined (from the subset ofcandidates or from all of the array's encoding elements), the identityof the encoding element may be automatically stored at block 1550, e.g.,in a memory element 1240 of the encoding module illustrated in FIG. 13or elsewhere. In subsequent operations, the processor may identify asecond or subsequent media unit to be processed and use the storedinformation to determine the optimal encoding element without requiringanother calibration method.

The calibration method may be applied to a first media unit to determinethe optimal encoding element for the transponder of the first mediaunit. In some embodiments, such as an RFID printer-encoder, a pluralityof media units can be processed in series one transponder at a timeand/or one row of transponders at a time. The plurality of media unitsare often of the same type and having the same type of transponder.Therefore, the processor may select the optimal encoding elementdetermined for the first media unit as the default encoding element forcommunicating with subsequent transponders moving along the feed path tobe encoded at block 1550.

The optimal encoding element(s) determined for the first media unit maybe automatically save to nonvolatile memory and subsequently selected asthe encoding element(s) for any subsequent transponders until theprocessor identifies another event, referred to as a reset event 1560.For example, the processor may use the optimal encoding elementdetermined for the first media unit as the default encoding elementuntil the processor identifies or receives information regarding one ormore unsuccessful communication attempts or other communication errors.Once the processor identifies one or more communication errors, theprocessor may cause the calibration method to repeat.

Rather than or in addition to the calibration method performed by theprocessor, an operator may manually control the position of the media(by, e.g., effectively moving the media to align the transpondersoptimally with one or more encoding elements), and then selectivelyactivate the one or more of encoding elements through an operator inputelement or interface of the printer-encoder, e.g., a keypad. Inembodiments that provide both automatic and manual calibration, one orthe other may be preconfigured as the default process. A preconfigurednaming scheme may allow the operator to easily communicate with theencoding module, and enable the encoding module to identify a particularencoding element or elements to be used to couple with the transponders.For example, the operator may identify the encoding element or devicesby row and column (e.g., A2 may select the second element in row A). Asanother example, the operator may identify the type of media unit. Oncethe media unit is identified the processor may be configured to identifythe optimal encoding element in accordance with data stored in thememory, e.g., a look-up table. The look-up table can be one of manymeans for the operator to view the settings for one or more the encodingelements 1210. The look-up table, similar to other data stored inmemory, can be viewed over the network, on a display integrated into thesystem, by way of a configuration label or by any other means. Inaddition to the look-up table, a history of each element used forencoding can be logged in memory. The history log can be presented tothe operator in response to the operator indicating a desire to view thehistory log. By providing the operator direct control of and access tothe encoding module, the system can allow for quicker setup of known ordesired configurations, such as those used for compliance andengineering testing.

In yet another example, a system, such as a printer-encoder, may includean encoding element and a reader configured to read information from aspecifically dedicated identification transponder associated with thesupply of media units. The system's supply of media units may include,for example, a roll and an identification transponder attached to theroll. The identification transponder may include information, amongother things, about the media unit, including the type of the mediaunit. The coupler and reader of the printer-encoder may be able toretrieve the information from the identification transponder, therebyallowing the system's processor to identify the type of media unit to beprocessed and select the most suitable encoding element or elements,e.g., depending on width of media and type and placement of thetransponder.

Referring back to the operation of attempting to communicate with thetransponder of first media unit through at least one or more of theplurality of encoding elements 1520, the number of encoding elementsused and the order in which the encoding elements are tested may vary.For example, according to an embodiment, an attempt to communicate withthe transponder may be made through each encoding element of the array.The attempts may occur in order of column and row, e.g., the order maybe A1, A2, A3, A4, B1, B2, B3, and so on until each encoding element istested. As another example, a subset of the encoding elements may betested according to an algorithm that selects one or more of theelements for testing (thereby selectively omitting one or more of theencoding elements from testing). A “test” refers to an attempt tocommunicate with a transponder through a particular connected element orelements at a particular power level.

The order or sequence of testing encoding elements may be according tothe probability of an encoding element being an optimal encodingelement. The system's memory element may store information regarding themost likely encoding elements to be an optimal encoding element, whichmay be based on the most common media unit used. For example, themanufacturer of the printer-encoder may provide this information basedon sales or customer feedback. As another example, a user may providethis information based on the user's preferences or intent. Based on themost common media units, the processor may be able to determine the mostlikely optimal encoding elements, e.g., through a look-up table storedin the memory element. As yet another example, the processor may monitorand store which encoding elements were considered optimal encodingelements in the past (based on, e.g., past operations of theprinter-encoder system), such as the type of supplies used, variabledata printed, label design format, descriptive data, XML schema, printdate, print time, format date, printing location, operator, IP address,printing application, printing mode (e.g., DT/TT, cut, rewind, peel,etc.), environmental conditions, and/or other operational data.

Once an encoding element is successful in communicating to thetransponder, the adjacent encoding elements may be tested. If a secondadjacent encoding element is successful, then one or more additionalencoding elements (adjacent to the second encoding element) may also betested. If the second adjacent encoding element is unsuccessful, thenthe processor may determine to forgo testing additional encodingelements that are adjacent to the second encoding element, but notadjacent to the first encoding element. In other words, the system'salgorithm may be configured to specifically choose which encodingelements to test and/or not to test, based on the successful orunsuccessful attempts by other encoding elements.

In the embodiment illustrated in FIG. 12, the array includes fourcolumns and four rows of encoding elements for a total of sixteenencoding elements. In other embodiments, the number of columns, rows,and encoding elements may vary. For example, the number of encodingelements per column or row may vary such that one column or row may havemore or less encoding elements than another column or row. The size andshape of the array and the encoding elements may be according to thespace available in the system, cost considerations, or the likely mediaunits to be processed by the system.

Moreover, as illustrated in FIGS. 19a through 19b , the rows and columnsmay be offset from another. As indicated with the arrows, in theembodiment illustrated in FIG. 19a , the rows and columns are alignedwith each other, which represents an array 1900 of a plurality ofencoding elements 1910 wherein each encoding element is centered witheach adjacent encoding element. Again as indicated with the arrows, inthe embodiments illustrated in FIGS. 19b and 19c , the columns and rowsare offset from each other such that each encoding element is notcentered with each adjacent encoding element. For example, in FIG. 19b ,the adjacent columns are offset from each other such that the center ofan encoding element is centered between the ends of two encodingelements of the adjacent column. In FIG. 19c , every other column hasrelatively smaller encoding elements creating an offset arrangement.

The above encoding elements and modules are configured to allow for theencoding of more types and sizes of media units and transponders. Moreparticularly, the typical conventional encoding systems include RFIDReaders and antennas based on transmission lines, coplanar waveguides,striplines, and other microwave structures. These conventional systemsimpose strict limitations on the dimensions of the media units and thespacing between adjacent media units. The conventional systems are alsonot capable of encoding small transponders on their natural pitch. Forrelatively long media units, a position for every transponder isrestricted by its individual specification for different models of bothHF and UHF RFID printer-encoders.

The encoding module disclosed herein is capable of encoding both dry andwet inlays on pitch and transponders embedded in relatively long labelswith independent orientation and position. As discussed above, theencoding module may include a reader and a 2D array or matrix ofmagnetic field encoding elements. Each encoding element of the array maybe activated sequentially. The reader response allows for determining atransponder position or placement, selecting the optimal encodingelement, and analysis of RF operational power level with a sufficientmargin. All these measures secure a robust encoding of the detectedtransponder.

In some embodiments, multiple encoding elements can be used to encodemultiple transponders while the media remains stationary. For example, aRFID printer-encoder system may include a number of encoding elements(as shown in, e.g., FIG. 12) that are arranged in a pattern similar tothe transponders arranged on the media. The system may receive (e.g.,passively accept and/or actively pull) media having the transponders onit into the system. In response to the system determining that themedia's transponders are aligned accordingly with respect to thesystem's encoding elements, encode all of the media's transponders enmasse. While the transponders can be quickly encoded en masse, byactivating a each encoding element one at a time, to avoid creatingnoise and interfering with the encoding of adjacent transponders. Themass-encoding process may occur during a single pause in movement of themedia through the system. Once the encoding of all the media'stransponders is complete, the system may then eject the media from theencoding zone of the system, receive another media, and repeat.

For example, a series of small item button type transponders can bespaced on a media to match the spacing of encoding elements 1210 (i.e.,A1, A2, A3, . . . , D3 and D4) of encoding module 1200. All of thebutton type transponders can then be encoded with only stopping themedia's movement once. As such, sixteen button type transponders areencoded without moving the media, which may be useful in, e.g., highvolume transponder production for package validation applications. Asanother example, media having both a dipole type transponder and buttontype transponders could be programmed simultaneously with the mediastopping only once while moving through the encoder-printer system.During a single stop, the dipole transponder could be programmed by oneof the encoding elements 1210 (e.g., D4) and a corresponding button typetransponder could be programmed by another one of the encoding elements(e.g., A4). The dipole transponder encoded by D4 could then be used forlong range identification while the button transponder encoded by A4could be used for authentication.

Access Control and Encoding Module

In another embodiment, such as the one illustrated in FIGS. 16 through18, an access card 1600 and encoding module 1700 are provided. Theaccess card 1600 includes a plurality of transponders 1610. For example,the access card 1600 may include a laminated structure having a toplayer, a bottom layer, and the plurality of transponders 1610 betweenthe top and bottom layers. The encoding module 1700 includes a pluralityof encoding elements 1710, such as loop co-planar waveguides. Eachencoding element is configured to have a limited range such that eachencoding element can be selectively activated and communicative with onetransponder at a time that is in proximity to it. As an example, each ofthe encoding elements may be any of the encoding elements illustrated inFIGS. 2A-B and 7A-8B. The locations of the transponders on the accesscard may be configured to correspond to the locations of the encodingelements on the encoding module.

The encoding module may form part of an access control system 1800. Inorder to gain access to a particular area, the user or wearer of theaccess card 1600 has to place the access card 1600 near the encodingmodule 1700. For example, the encoding module 1700 may include a slot1720 configured to receive the access card 1600. Once the access card isinserted into the slot, a reader 1810 can attempt to communicate witheach of the transponders 1610 of the access card through the encodingelements 1710 of the encoding module. If the access card is proper, thetransponders are positioned such that the communication is possiblebecause the transponders and the encoding elements are aligned. If theaccess card is not proper, e.g., a forgery, it is less likely the numberand location of the transponders are consistent with the encodingmodule. Therefore, the access control system 1800 is more likely todetect the improperness of the access card and deny access. The accesscard may incorporate additional authentication features as furtherdisclosed in commonly owned U.S. Pat. No. 7,137,000 which is herebyincorporated herein by reference in its entirety. For example, for everytransponder, the algorithm of generating a password might be differentwhich further complicate efforts to develop counterfeits.

As with conventional cards, the transponders may also containinformation that confirms the proper access for the user or wearer. Theencoding module and access card of the embodiment illustrated in FIGS.16 through 18 provide an additional layer of security by requiring aplurality of transponders in a particular arrangement to allow access.The number and pattern of transponders and encoding elements may vary.For example, the transponders and the encoding elements may be in anuncommon and uneven shape.

Modular Encoding Elements or Coupling Devices

As discussed above, the preferred location and type of each encodingelement may depend on the placement and type of each transponder.Embodiments disclosed herein address this challenge by providing anarray of encoding elements in which the connected encoding elements maybe varied accordingly.

In addition to or rather than providing the array, embodiments mayprovide a common connector for various types and size encoding elementsor coupling devices. For example, as illustrated in the embodiments ofFIGS. 20a through 21, the system 2100, such as a printer-encoder, mayinclude or define an adapter 2110. The adapter 2110 is specificallyconfigured to receive and engage a particular shape and size connector2020 of a coupling device such that, once the connector 2020 engages theadapter 2100, an electrical connection is formed between the couplingdevice and the system 2100 or more specifically the reader of thesystem. Although the coupling devices 2000, 2001, 2002 of FIGS. 20athrough 20c differ in size, shape, and type, each can include the sametype of connector 2020 configured for the adapter 2110 of the system.Therefore, due to the use of a common type of connector 2020, the systemmay use various sizes, shapes, and types of coupling devices dependingon the placement and type of transponders to be processed.

For example, different encoding modules as disclosed may beinterchangeable. A first encoding module may have an array such as theone illustrated in FIG. 19a and the second encoding module may have anarray such as the one illustrated in FIG. 19c . Because the first andsecond encoding modules have the same type of connector, a user mayeasily replace the first encoding module with the second encoding modulein a printer-encoder system, thereby allowing the system to accommodatedifferent types of transponders. As another example, a first type ofcoupling device and a second type of coupling device can be utilized.The first type of coupling device may be a co-planar waveguide and thesecond type of coupling device may be a loaded stripline. Because thetwo types of coupling devices have the same type of connector, a usermay manually replace or the system may automatically replace the firstcoupling device with the second coupling device to accommodate differenttypes of the transponders.

Smart Sweep

In addition to or as an alternative to the calibration process discussedabove (see, e.g., FIGS. 15A-15G), embodiments of the present inventioncan be configured to execute a smart sweep algorithm. While thetransponder calibration algorithm can be used to determine the idealencoding element, power setting, and encoding transponder position, thesmart sweep algorithm of FIG. 22 can provide the ability for aprinter-encoder or other system to function in an environment having acharacteristic sometimes referred to as a “transponder placementindependence,” which includes situations when transponders arepositioned vertically (along the feed line) on the media within acertain range (such as, e.g., within 15 mm to 60 mm) of each other. Thesmart sweep algorithm can be reserved for and/or most effective inembodiments utilizing media of a minimum length relative to the range(such as, e.g., 2 inches). For example, the smart sweep algorithm can beused with four-inch dipole transponders, three-inch dipole transponders,and/or high gain tag types.

Process 2200 of FIG. 22 shows one exemplary method that firmware,software, any other type of system (or component thereof), or anycombination thereof can be configured to execute. Process 2200effectively “sweeps” the encoding elements to find and encode atransponder. At block 2202, the process 2200 starts with the sweep valueset to false. The sweep value can be set to FALSE when, for example, theprinter head is closed or the system is initially powered ON.

Next, at block 2204, a format is received by the system for encoding amedia that is positioned or may be positioned with the media's leadingedge at the printer-encoder's printline. The format can be provided by,for example, a host computer, the printer-encoder's central processor, amemory component, any other electrical component, or any combinationthereof. As shown in FIG. 22, the format can be received whenever theprinter-encoder is powered ON. In some instances, a triggering event cancause the format to be received. Examples of trigger events include whenthe printer-encoder is initially powered ON and/or the printer head isopened. The format can be in the form of, for example, a ZPL command,any other type of command signal, or combination thereof.

The media can have an embedded or other type of transponder. At block2206, one of the encoding elements (“E”) is activated and attempts toencode the transponder using a particular amount of power (“P”). E canbe set at block 2206, for example, using the sweep series algorithmdiscussed herein, manually, and/or by using the transponder calibrationmethod; examples of both methods are discussed above in connection with,e.g., FIGS. 15A-15G. P can be set, for example, automatically by thesystem (using, e.g., the transponder calibration method) and/or manuallyin response to an input received from the operator.

Next, at block 2208, a determination is made as to whether the encodingof the transponder using E was successful. This determination can bemade after a predetermined number of retries. The number of retries canbe preconfigured into the system and/or be a manually set variable. Ifthe encoding was successfully performed within the number of allottedtries, the encoding process ends at block 2210. Accordingly, at block2210, the power supplied to E can be turned OFF or otherwise reduced.

Next in process 2200 is block 2212, in which a determination is made asto whether the media was greater than or equal to two inches (or anyother minimum size that can be preconfigured for each printer-encoderand/or each type of printer encoder, be set manually, and/or beautomatically determined based on any other variable(s)). If the mediais determined to be greater than two inches, process 2200 proceeds backto block 2202. In response to determining that the media is at least twoinches, process 2200 proceeds to block 2214 and the sweep value is setas TRUE, indicating that the sweep function was successfully performed.Process 2200 then proceeds to block 2228 where the media is ejected,printed on, or otherwise processed, and then process 2200 ends. Oneskilled in the art would appreciate that the amount of 2 inches is meantto be exemplary only of a minimum size. Different printing requirements,encoding element configurations, types of media, etc. can allow (and mayeven require) process 2200 to utilize one or more other lengthconfirmation determinations. Also, some embodiments of the presentinvention may provide for the omission of one or more of the stepsdiscussed herein.

Returning to block 2208, in response to a determination being made thatthe encoding was unsuccessful too many times, process 2200 proceeds toblock 2216. At block 2216, process 2200 determines whether or not themedia is greater than or equal to 2 inches in length. If the media isdetermined to be greater than two inches, process 2200 proceeds to block2218.

At block 2218, process 2200 determines whether or not sweep is currentlyset to the value FALSE. In response to determining sweep is set toFALSE, process 2200 moves to block 2220 and changes E to the nextencoding element in the sweep series. Also, the number of retries valueis reset to 0. This will enable the new E encoding element to have thesame number of retries as the pervious encoding element. In someembodiments, the system can be configured to set the new E to an encoderin columns 4 and 3 before moving onto columns 1 and 2. This may allowfor the array of encoding elements to do a front-to-back sweep of themedia. In other embodiments, the sweep can be performed in anydirection, including back-to-front, random selection, right-to-left,left-to-right, diagonally, a combination thereof, and/or by any otheralgorithm.

In response to determining at block 2218 that sweep is not set at FALSE,process 2200 proceeds to block 2224 and E is changed to be set as thenext encoding element, which can be chosen based on the same or adifferent algorithm than those discussed in connection with block 2220.For example, the next encoding element in the sweep series could bechosen based on a retry command, which can comprise an additional way tosweep after all the first set of retries have been unsuccessfullyexhausted. The operator, for example, could be given some level ofcontrol at block 2224 in defining what to do if the encoding elementarray fails to find and encode the transponder. This may include, forexample, receiving operator input of a particular encoding element (suchas, e.g., B4 or D4) if C4 was not encoding the transponder successfully.In some embodiments, the operator may also choose to void and abortprocess 2200, but giving the operator the opportunity to manually selectanother encoding element may help reduce the void rate. As anotherexample, the customer can select one or more algorithms (instead of oneor more particular encoding elements) to be used in selecting the next Ein the sweep series. The number of retries value is also set to zero atblock 2224. In some embodiments the number of retries value can be auser configurable value and/or any other number other than zero that canbe updated subsequent to the printer-encoder's manufacturer'sconfiguration.

After blocks 2224 and 2220, process 2200 proceeds to block 2222 anddetermines whether the sweep is complete. In response to determining thesweep is complete at block 2222 or subsequent to determining at block2216 that the media is less than 2 inches, process 2200 proceeds toblock 2226 at which the media is voided and the sweep value is set toFALSE. Process 2200 then proceeds to block 2228 (discussed above) andends.

Many combinations and modifications to the embodiments discussed hereinas well as other embodiments of the invention set forth herein will cometo mind to one skilled in the art having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Therefore, it is to be understood that the invention is not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theappended claims. Although specific terms are employed herein, they areused in a generic and descriptive sense only and not for purposes oflimitation.

That which is claimed:
 1. An encoding element comprising: a groundplane; a first dielectric substrate adjacent to the ground plane; aconductive strip adjacent the first dielectric substrate and extendingfrom an input end to a loaded end and comprising at least one portionhaving a loop shape; a terminating load in communication with the loadedend of the conductive strip a second dielectric substrate adjacent theconductive strip; and a shield adjacent an opposite surface of thesecond dielectric substrate from the conductive strip and generallycorresponding to the at least one portion having a loop shape of theconductive strip including providing a central open area.